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Thread: Casting aluminum in sand

  1. #1

    Casting aluminum in sand

    I have had some questions on the sand casting process here so I took some photos of the process to help demonstrate how it's done.

    Photo 1 is the two piece pattern.
    Photo 2 is the first half in the cope ready to add sand. (sand box half)
    Photo 3 is the same pattern half after adding sand (split half view)
    Photo 4 is the second half of the pattern locked on the first half embedded in the sand.
    Photo 5 is the two pattern halves embedded in the two piece sand box (called flask)
    More on next link.
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  2. #2
    Photo 6 shows the draw pins (screws) and pouring gate cut in the mold.
    Photo 7 is the sand cavity after pulling the pattern out of the cope.
    Photo 8 is the sand cavity after pulling the second half pattern out of the drag.
    Photo 9 is the casting with the gate and pouring sprue still attached.
    Photo 10 is the casting with the gate cut off.
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  3. #3
    Senior Member arandall's Avatar
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    Gadget:
    Where the h-- do you learn all this stuff?

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  4. #4
    I got the basics of sand casting in high school but learned the finer details from the Gingery books on foundry and the machine projects years ago.
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  5. #5
    What are the patterns made of? I was expecting wood but they don't look like wood.

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  6. #6
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    I learn something every day!! Thanks Gadget
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  7. #7
    I was one that asked the question. Now things are much more clear. Thanks for the detailed post.
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  8. #8
    Quote Originally Posted by matteh99 View Post
    What are the patterns made of? I was expecting wood but they don't look like wood.

    Eric
    The patterns are wood but are painted with a thick latex paint to prevent moisture absorption from the sand.
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  9. #9
    I too like those Gingery books.

    Once neede a one off cast aluminum part to repair a commercial laundry extractor for a friend.

    Made the form from the green styrafoam looking plastic that florists use.

    Just put in a cope made from 2x6s and plywood, tamped casting sand around it and put 2 sprus, one to pour, one to let gas escape.

    Made a ladle from a piece of pipe and used an old electric kiln to melt the aluminum

    Worked great, guess you could call it the lost foam method.

    Bill

  10. #10
    I'm working on a lost foam pattern for a blower right now. I have the drawing but need to get the program to convert it to Gcode for my CNC router to cut it.
    Units owned Longevity PROmts 200

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    Atlas 10x36" lathe
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    Home built aluminum foundry, HF 4x6 bandsaw

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